U.S. patent application number 10/337820 was filed with the patent office on 2003-06-19 for coating system for a porous substrate using an asphalt-containing thermosetting basecoat composition and a thermoplastic top coat composition.
Invention is credited to Clemens, Leslie G., Clemens, Paul L..
Application Number | 20030113566 10/337820 |
Document ID | / |
Family ID | 22961515 |
Filed Date | 2003-06-19 |
United States Patent
Application |
20030113566 |
Kind Code |
A1 |
Clemens, Paul L. ; et
al. |
June 19, 2003 |
Coating System for a Porous Substrate Using an Asphalt-Containing
Thermosetting Basecoat Composition and a Thermoplastic Top Coat
Composition
Abstract
A coating system comprises a basecoat of an thermosetting
asphalt extended, chemically cross linked--urethane/epoxy hybrid
basecoat resting on a substrate, preferably a porous substrate such
as concrete or wood that off-gas when coated with a thermoplastic
material; and a thermoplastic powder coating topcoat overlying at
least the base coat. The thermosetting basecoat composition
consisting essentially of, in weight percent based on final
formulation, and between 10 and 90% of a petroleum asphalt; between
10 and 90%, of a hydroxy-terminated homopolymer; and between 0.1
and 30% of a functional epoxy reactive diluent for reducing the
viscosity of the composition; and further up to 5% of a surfactant
for improving surface imperfections, up to 5% of an anti-oxidant;
and up to 25% of a thickening agent.
Inventors: |
Clemens, Paul L.; (Brush
Prairie, WA) ; Clemens, Leslie G.; (Brush Prairie,
WA) |
Correspondence
Address: |
CLARK & BRODY
SUITE 600
1750 K STREET, NW
WASHINGTON
DC
20006
US
|
Family ID: |
22961515 |
Appl. No.: |
10/337820 |
Filed: |
January 8, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10337820 |
Jan 8, 2003 |
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09994787 |
Nov 28, 2001 |
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6544596 |
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60253738 |
Nov 29, 2000 |
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Current U.S.
Class: |
428/497 ;
427/272; 427/282; 427/407.1; 428/498 |
Current CPC
Class: |
B05D 7/148 20130101;
Y10T 428/31511 20150401; B05D 3/08 20130101; C08G 18/698 20130101;
Y10T 428/31844 20150401; Y10T 428/249987 20150401; Y10T 428/31855
20150401; Y10T 428/31573 20150401; Y10T 428/31848 20150401; Y10T
428/31551 20150401; C09D 175/04 20130101; C08G 18/003 20130101;
B05D 7/54 20130101; B05D 1/10 20130101 |
Class at
Publication: |
428/497 ;
427/282; 427/272; 427/407.1; 428/498 |
International
Class: |
B05D 001/32; B05D
001/36 |
Claims
1. A coating system comprising: a) basecoat of an thermosetting
asphalt extended, chemically cross linked--urethane/epoxy hybrid
basecoat resting on a substrate, preferably a porous substrate such
as concrete or wood that off-gas when coated with a thermoplastic
material; and b) a thermoplastic powder coating topcoat overlying
at least the base coat.
2. The system of claim 1, wherein an alcohol-silane primer is on
the substrate and surrounds at least a portion of the basecoat
while leaving a portion of the substrate exposed, the topcoat
overlying both the primer and the portion of exposed substrate.
3. A thermosetting basecoat composition comprising, in weight
percent based on final formulation: a) between 10 and 90%,
preferably 20 and 70, and most preferably 30 and 60% of a petroleum
asphalt; b) between 10 and 90%, preferably 20 and 70, and most
preferably 30 and 60% of a hydroxy-terminated homopolymer; c)
between 0.1 and 30%, preferably 3 and 25, and most preferably 5 and
15% of a functional epoxy reactive diluent for reducing the
viscosity of the composition; d) up to 5%, preferably 0.2 and 3%,
and most preferably 0.3 and 1.0% of a surfactant for improving
surface imperfections; e) up to 5%, preferably 0.2 and 3%, and most
preferably 0.3 and 1.0% of an anti-oxidant; and f) up to 25%,
preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an
thickening agent.
4. The basecoat composition of claim 3, optionally including one or
more of a catalyst in a range between 0.0001 and 5%, preferably
0.005 and 2%, and most preferably 0.1 and 2.0%, polyols for higher
strength, other fillers for viscosity adjustment between 0.1 and
75%, functional silanes at 0.001 to 10%, thermal conductivity
agents between 0.1 and 75% of the formulation such as zinc oxide
for resiliency and conductivity, other fillers such as hollow
and/or solid glass spheres (0.001 to 5%), drying agents ranging up
to 20 gram/gram of water present, flame retardants in amounts
between 0.1 and 60%, corrosion inhibitors ranging from 0.1 and 50%,
antistatic agents ranging from 0.1 to 50%, biostabilizers ranging
from 0.1 to 10%, chemical blowing agents ranging from 0.1 to 10%,
scent additives ranging from 0.1 to 25%, bittering agents ranging
from 0.1 to 25%, pigments ranging from 0.1 to 40%, fluorescent
whiting agents, ranging from 0.1 to 10%, lubricants, UV stabilizers
ranging from 0.001% to 50%, powdered (-20 to -1250 mesh size)
thermoplastic materials and optionally 0.001% to 50%, powdered
thermoplastic with incorporation of one or more of the following:
fillers, thermal conductivity agents, flame retardants, corrosion
inhibiters, antistatic agents, biostabilizers, chemical blowing
agents, scent additives, bittering agents and pepper,
pigments/effects, fluorescent whiting agents, lubricants,
plasticizers, etc. (-20 to -1250 mesh size), and plasticizers each
ranging from 0.1 to 25%.
5. A preferred topcoat thermoplastic composition comprising, in
weight percent, based on final formulation: a) between 10 and 90%,
preferably 20 and 70, and most preferably 30 and 60% of a modified
ethylene terpolymer with a temperature stable ester and high acidic
functionality; b) between 5 and 95, preferably 20 and 70, and most
preferably 30 and 60% of a polyethylene/methacrylic acid copolymer;
c) between 5 and 95, preferably 5 and 70, and most preferably 7.5
and 20% of a polyethylene/methacrylic acid copolymer ionomer; d) up
to 50% of a coloring pigment; e) up to 5% of an anti-oxidant; f) up
to 5% of an ultraviolet stabilizer; g) up to 5%, preferably 0.2 and
3%, and most preferably 0.3 and 1.0% of a surfactant for improving
surface imperfections; and h) up to 25%, preferably 0.1 and 10%,
and most preferably 0.5 and 2.0% of an thickening agent.
6. The topcoat composition of claim 5, wherein the composition
optionally contains one or more of other fillers for viscosity
adjustment between 0.1 and 75%, thermal conductivity agents between
0.1 and 75% of the formulation such as zinc oxide for resiliency
and conductivity, drying agents ranging up to 20 gram/gram of water
present, flame retardants in amounts between 0.1 and 60%, corrosion
inhibitors ranging from 0.1 and 50%, antistatic agents ranging from
0.1 to 50%, biostabilizers ranging from 0.1 to 10%, chemical
blowing agents ranging from 0.1 to 10%, scent additives ranging
from 0.1 to 25%, bittering agents ranging from 0.1 to 25%, pigments
ranging from 0.1 to 40%, fluorescent whiting agents, raging from
0.1 to 10%, and lubricants, and plasticizers each ranging from 0.1
to 25%.
7. A primer composition for use with the composite coating system
employing a thermosetting resin basecoat and a heat-applied
thermoplastic resin overlying the basecoat of claim 1, the primer
consisting essentially, in weight percent, of between zero and up
to 10% of a silane, a solvent ranging between 80 and 95%, and the
balance water.
8. The primer of claim 7, wherein the silane is one of: an ionic
and anionic silane; a methanol, organic phosphonium chloride salt
and silane monomer; or any other silane having an active
hydrogen.
9. A method of coating at least a portion of a substrate by: a)
first mixing a thermosetting basecoat composition with an
isocyanate hardener to form a thermosetting mixture, the
thermosetting basecoat composition comprising, in weight percent
based on final formulation: between 10 and 90%, preferably 20 and
70, and most preferably 30 and 60% of a petroleum asphalt; between
10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of
a hydroxy-terminated homopolymer; between 0.1 and 30%, preferably 3
and 25, and most preferably 5 and 15% of a functional epoxy
reactive diluent for reducing the viscosity of the composition; up
to 5%, preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a
surfactant for improving surface imperfections; up to 5%,
preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of an
anti-oxidant; and up to 25%, preferably 0.1 and 10%, and most
preferably 0.5 and 2.0% of an thickening agent; b) applying the
basecoat as a liquid to a substrate, preferably a porous substrate
and allowing the basecoat to chemically crosslink to form a heat
dampening basecoat; c) thermally applying a topcoat thermoplastic
composition onto the heat dampening basecoat to a given thickness
to coat the substrate, the topcoat thermoplastic composition
comprising, in weight percent, based on final formulation: between
10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of
a modified ethylene terpolymer with a temperature stable ester and
high acidic functionality; between 5 and 95, preferably 20 and 70,
and most preferably 30 and 60% of a polyethylene/methacrylic acid
copolymer; between 5 and 95, preferably 5 and 70, and most
preferably 7.5 and 20% of a polyethylene/methacrylic acid copolymer
ionomer; up to 50% of a coloring pigment; up to 5% of an
anti-oxidant; up to 5% of an ultraviolet stabilizer; up to 5%,
preferably 0.2 and 3%, and most preferably 0.3 and 1.0% of a
surfactant for improving surface imperfections; and up to 25%,
preferably 0.1 and 10%, and most preferably 0.5 and 2.0% of an
thickening agent.
10. The method of claim 9, wherein the portion of the substrate is
masked prior to step (b).
11. The method of claim 9, wherein the substrate is masked twice,
the second mask covering both a first mask and a part of the
substrate, the second mask removed after step (b) to expose the
part of the substrate for step (c).
12. The method of claim 9, wherein the basecoat composition
optionally including one or more of a catalyst in a range between
0.0001 and 5%, preferably 0.005 and 2%, and most preferably 0.1 and
2.0%, polyols for higher strength, other fillers for viscosity
adjustment between 0.1 and 75%, functional silanes at 0.001 to 10%,
thermal conductivity agents between 0.1 and 75% of the formulation
such as zinc oxide for resiliency and conductivity, other fillers
such as hollow and/or solid glass spheres (0.001 to 5%), drying
agents ranging up to 20 gram/gram of water present, flame
retardants in amounts between 0.1 and 60%, corrosion inhibitors
ranging from 0.1 and 50%, antistatic agents ranging from 0.1 to
50%, biostabilizers ranging from 0.1 to 10%, chemical blowing
agents ranging from 0.1 to 10%, scent additives ranging from 0.1 to
25%, bittering agents ranging from 0.1 to 25%, pigments ranging
from 0.1 to 40%, fluorescent whiting agents, ranging from 0.1 to
10%, lubricants, UV stabilizers ranging from 0.001% to 50%,
powdered (-20 to -1250 mesh size) thermoplastic materials and
optionally 0.001 % to 50%, powdered thermoplastic with
incorporation of one or more of the following: fillers, thermal
conductivity agents, flame retardants, corrosion inhibiters,
antistatic agents, biostabilizers, chemical blowing agents, scent
additives, bittering agents and pepper, pigments/effects,
fluorescent whiting agents, lubricants, plasticizers, etc. (-20 to
-1250 mesh size), and plasticizers each ranging from 0.1 to
25%.
13. The method of claim 9, wherein the topcoat thermoplastic
composition is modified with the incorporation of one or more of
other fillers for viscosity adjustment between 0.1 and 75%, thermal
conductivity agents between 0.1 and 75% of the formulation such as
zinc oxide for resiliency and conductivity, drying agents ranging
up to 20 gram/gram of water present, flame retardants in amounts
between 0.1 and 60%, corrosion inhibitors ranging from 0.1 and 50%,
antistatic agents ranging from 0.1 to 50%, biostabilizers ranging
from 0.1 to 10%, chemical blowing agents ranging from 0.1 to 10%,
scent additives ranging from 0.1 to 25%, bittering agents ranging
from 0.1 to 25%, pigments ranging from 0.1 to 40%, fluorescent
whiting agents, ranging from 0.1 to 10%, and lubricants, and
plasticizers each ranging from 0.1 to 25%.
14. The system of claim 1, further comprising a reinforcing layer
disposed between the basecoat and the topcoat.
15. The system of claim 14, wherein the reinforcing layer is one of
a metallic or non-metallic fiber such as glass, a natural fiber
such as cotton, a polymeric fiber, a carbon fiber, or combinations
thereof.
16. The method of claim 9, wherein a reinforcing material is
applied on the basecoat and before the topcoat.
17. The basecoat of claim 3, comprising an effective amount of a
hardener to cross link with the hydroxyl functional polybutadiene
and reactive diluent components and active hydrogen contained in
the asphalt, wherein the hardener is preferably an isocyanate type
hardener, but can be diamine or an equivalent hardener.
18. A method of coating at least a portion of a substrate by: a)
first mixing a basecoat thermosetting composition with an
isocyanate hardener to form a thermosetting mixture and storing the
mixture in the absence of atmospheric moisture; the basecoat
thermosetting composition the thermosetting basecoat composition
comprising, in weight percent based on final formulation: between
10 and 90%, preferably 20 and 70, and most preferably 30 and 60% of
a petroleum asphalt; between 10 and 90%, preferably 20 and 70, and
most preferably 30 and 60% of a hydroxy-terminated homopolymer;
between 0.1 and 30%, preferably 3 and 25, and most preferably 5 and
15% of a functional epoxy reactive diluent for reducing the
viscosity of the composition; up to 5%, preferably 0.2 and 3%, and
most preferably 0.3 and 1.0% of a surfactant for improving surface
imperfections; up to 5%, preferably 0.2 and 3%, and most preferably
0.3 and 1.0% of an anti-oxidant; and up to 25%, preferably 0.1 and
10%, and most preferably 0.5 and 2.0% of an thickening agent; b)
applying the mixture to a substrate, preferably a porous substrate
and allowing the basecoat to chemically crosslink to form, a heat
dampening basecoat; and c) thermally applying a topcoat
thermoplastic composition onto the heat dampening basecoat to a
given thickness to coat the substrate, the topcoat thermoplastic
composition comprising, in weight percent, based on final
formulation: between 10 and 90%, preferably 20 and 70, and most
preferably 30 and 60% of a modified ethylene terpolymer with a
temperature stable ester and high acidic functionality; between 5
and 95, preferably 20 and 70, and most preferably 30 and 60% of a
polyethylene/methacrylic acid copolymer; between 5 and 95,
preferably 5 and 70, and most preferably 7.5 and 20% of a
polyethylene/methacrylic acid copolymer ionomer; up to 50% of a
coloring pigment; up to 5% of an anti-oxidant; up to 5% of an
ultraviolet stabilizer; up to 5%, preferably 0.2 and 3%, and most
preferably 0.3 and 1.0% of a surfactant for improving surface
imperfections; and up to 25%, preferably 0.1 and 10%, and most
preferably 0.5 and 2.0% of an thickening agent.
19. The method of claim 18, wherein a reinforcing material is
applied on the basecoat and before the topcoat.
Description
[0001] This application is a divisional application of Ser. No.
09/994,787 filed on Nov. 28, 2001, which is based on provisional
patent application No. 60/253,738 filed on Nov. 29, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to an engineered composite
system, system component compositions and methods of use, and in
particular to a system employing a thermosetting asphalt extended
cross-linked hybrid basecoat for resting on a porous substrate, and
for receiving a thermoplastic top coating.
BACKGROUND OF THE INVENTION
[0003] A number of coating materials have been proposed for thermal
field applied applications, particularly flame-sprayed coatings.
One problem with these types of field-applied coatings is that the
substrate may be porous, e.g., wood or concrete, and is subject to
off-gassing or thermal decomposition. Consequently, it is very
difficult to coat these types of materials.
[0004] Accordingly, there exists a need for improved coating
systems and compositions to solve the problem of coating porous
substrates.
[0005] The present invention solves this need by providing a field
applied coating system that is ideally adapted for porous
substrates.
SUMMARY OF THE INVENTION
[0006] It is a first object of the present invention to provide an
improved field applied engineered composite system coating.
[0007] Another object of the invention is a field applied and/or
shop applied, engineered composite system comprising: 1) an asphalt
extended, chemically cross linked--urethane/epoxy hybrid basecoat,
2) an alcohol/silane primer, 3) a thermoplastic powder coating
topcoat, 4) a optional fabric or fiber reinforcement layer, and the
system components of the basecoat, the topcoat, and the primer.
[0008] Other objects and advantages of the present invention will
become apparent as a description thereof proceeds.
[0009] In satisfaction of the foregoing objects and advantages, the
present invention provides a coating system that comprises a
basecoat of an thermosetting asphalt extended, chemically cross
linked--urethane/epoxy hybrid basecoat resting on a substrate,
preferably a porous substrate such as concrete or wood that off-gas
when coated with a thermoplastic material; and a thermoplastic
powder coating topcoat overlying at least the base coat. An
alcohol-silane primer can be on the substrate and surrounding at
least a portion of the basecoat while leaving a portion of the
substrate exposed, the topcoat overlying both the primer and the
portion of exposed substrate.
[0010] The system can further comprise a reinforcing layer disposed
between the basecoat and the topcoat, and the reinforcing layer can
be one of a metallic or non-metallic fiber such as glass, a natural
fiber such as cotton, a polymeric fiber, a carbon fiber, or
combinations thereof.
[0011] The thermosetting basecoat composition comprises, in weight
percent based on final formulation:
[0012] between 10 and 90%, preferably 20 and 70, and most
preferably 30 and 60% of a petroleum asphalt;
[0013] between 10 and 90%, preferably 20 and 70, and most
preferably 30 and 60% of a hydroxy-terminated homopolymer;
[0014] between 0.1 and 30%, preferably 3 and 25, and most
preferably 5 and 15% of a functional epoxy reactive diluent for
reducing the viscosity of the composition;
[0015] up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and
1.0% of a surfactant for improving surface imperfections;
[0016] up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and
1.0% of an anti-oxidant; and
[0017] up to 25%, preferably 0.1 and 10%, and most preferably 0.5
and 2.0% of an thickening agent.
[0018] The basecoat can also comprise an effective amount of a
hardener to cross link with the hydroxyl functional polybutadiene
and reactive diluent components and active hydrogen contained in
the asphalt, wherein the hardener is preferably an isocyanate type
hardener, but can be diamine or an equivalent hardener.
[0019] The basecoat composition can optionally including one or
more of a catalyst in a range between 0.0001 and 5%, preferably
0.005 and 2%, and most preferably 0.1 and 2.0%, polyols for higher
strength, other fillers for viscosity adjustment between 0.1 and
75%, functional silanes at 0.001 to 10%, thermal conductivity
agents between 0.1 and 75% of the formulation such as zinc oxide
for resiliency and conductivity, other fillers such as hollow
and/or solid glass spheres (0.001 to 5%), drying agents ranging up
to 20 gram/gram of water present, flame retardants in amounts
between 0.1 and 60%, corrosion inhibitors ranging from 0.1 and 50%,
antistatic agents ranging from 0.1 to 50%, biostabilizers ranging
from 0.1 to 10%, chemical blowing agents ranging from 0.1 to 10%,
scent additives ranging from 0.1 to 25%, bittering agents ranging
from 0.1 to 25%, pigments ranging from 0.1 to 40%, fluorescent
whiting agents, ranging from 0.1 to 10%, lubricants, UV stabilizers
ranging from 0.001% to 50%, powdered (-20 to -1250 mesh size)
thermoplastic materials and optionally 0.001% to 50%, powdered
thermoplastic with incorporation of one or more of the following:
fillers, thermal conductivity agents, flame retardants, corrosion
inhibiters, antistatic agents, biostabilizers, chemical blowing
agents, scent additives, bittering agents and pepper,
pigments/effects, fluorescent whiting agents, lubricants,
plasticizers, etc. (-20 to -1250 mesh size), and plasticizers each
ranging from 0.1 to 25%.
[0020] A topcoat thermoplastic composition comprises, in weight
percent, based on final formulation:
[0021] between 10 and 90%, preferably 20 and 70, and most
preferably 30 and 60% of a modified ethylene terpolymer with a
temperature stable ester and high acidic functionality;
[0022] between 5 and 95, preferably 20 and 70, and most preferably
30 and 60% of a polyethylene/methacrylic acid copolymer;
[0023] between 5 and 95, preferably 5 and 70, and most preferably
7.5 and 20% of a polyethylene/methacrylic acid copolymer
ionomer;
[0024] up to 50% of a coloring pigment;
[0025] up to 5% of an anti-oxidant;
[0026] up to 5% of an ultraviolet stabilizer;
[0027] up to 5%, preferably 0.2 and 3%, and most preferably 0.3 and
1.0% of a surfactant for improving surface imperfections; and
[0028] up to 25%, preferably 0.1 and 10%, and most preferably 0.5
and 2.0% of a thickening agent.
[0029] The topcoat composition can optionally contain one or more
of other fillers for viscosity adjustment between 0.1 and 75%,
thermal conductivity agents between 0.1 and 75% of the formulation
such as zinc oxide for resiliency and conductivity, drying agents
ranging up to 20 gram/gram of water present, flame retardants in
amounts between 0.1 and 60%, corrosion inhibitors ranging from 0.1
and 50%, antistatic agents ranging from 0.1 to 50%, biostabilizers
ranging from 0.1 to 10%, chemical blowing agents ranging from 0.1
to 10%, scent additives ranging from 0.1 to 25%, bittering agents
ranging from 0.1 to 25%, pigments ranging from 0.1 to 40%,
fluorescent whiting agents, raging from 0.1 to 10%, and lubricants,
and plasticizers each ranging from 0.1 to 25%.
[0030] A primer composition for use with the composite coating
system employing a thermosetting resin basecoat and a heat-applied
thermoplastic resin overlying the basecoat consists essentially, in
weight percent, of between zero and up to 10% of a silane, a
solvent ranging between 80 and 95%, and the balance water. The
silane can be one of: an ionic and anionic silane; a methanol,
organic phosphonium chloride salt and silane monomer; or any other
silane having an active hydrogen.
[0031] The method also entails coating at least a portion of a
substrate by first mixing the basecoat composition with or without
the optional ingredients noted above with an isocyanate hardener to
form a thermosetting mixture. The basecoat is applied as a liquid
to a substrate, preferably a porous substrate and the basecoat is
allowed to chemically crosslink to form a heat dampening basecoat.
Then, the topcoat of claims with or without the optional
ingredients is thermally applied onto the heat dampening basecoat
to a given thickness to coat the substrate. A portion of the
substrate can be masked prior to basecoat application. Preferably,
the substrate is masked twice, the second mask covering both a
first mask and a part of the substrate, the second mask removed
after basecoat application to expose the part of the substrate for
topcoat application.
[0032] One or more of the resin components of the topcoat
composition with or without the optional ingredients can be
substituted with one or more of the polymers as detailed below.
[0033] The topcoat composition can be further modified with the
incorporation of one or more of other fillers for viscosity
adjustment between 0.1 and 75%, thermal conductivity agents between
0.1 and 75% of the formulation such as zinc oxide for resiliency
and conductivity, drying agents ranging up to 20 gram/gram of water
present, flame retardants in amounts between 0.1 and 60%, corrosion
inhibitors ranging from 0.1 and 50%, antistatic agents ranging from
0.1 to 50%, biostabilizers ranging from 0.1 to 10%, chemical
blowing agents ranging from 0.1 to 10%, scent additives ranging
from 0.1 to 25%, bittering agents ranging from 0.1 to 25%, pigments
ranging from 0.1 to 40%, fluorescent whiting agents, ranging from
0.1 to 10%, and lubricants, and plasticizers each ranging from 0.1
to 25%.
[0034] The invention also entails a method of coating at least a
portion of a substrate by first mixing the basecoat composition as
defined above with an isocyanate hardener to form a thermosetting
mixture, and storing the mixture in the absence of atmospheric
moisture. Then, the mixture is applied to a substrate, preferably a
porous substrate and the basecoat is allowed to chemically
crosslink to form a heat dampening basecoat. Then, the topcoat as
noted above is thermally applied onto the heat dampening basecoat
to a given thickness to coat the substrate. In this method, a
reinforcing material can be applied on the basecoat and before the
topcoat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is an example of a side profile of a coating
system.
[0036] FIG. 2 is an example of a fluid bed dipping coating
technique.
[0037] FIG. 3 is one method of an electrostatic spray coating
technique.
[0038] FIG. 4 is a second method of an electrostatic spray coating
technique.
[0039] FIG. 5 is one method of an electrostatic fluid-bed coating
technique.
[0040] FIG. 6 is a second method of an electrostatic fluid-bed
coating technique.
[0041] FIG. 7 is one method of a tribostatic spray coating
technique.
[0042] FIG. 8 is a second method of a tribostatic spray coating
technique.
[0043] FIG. 9 is an example of a flocking spray coating
technique.
[0044] FIG. 10 is an example of a flame- and arc-spray coating
technique.
DETAILED DESCRIPTION OF THE INVENTION
[0045] This invention, when used as a field applied/shop applied
coating system, allows the user to thermally deposit (via flame
spray technology, arc-spray technology, and other thermal
application equipment) a thermoplastic powder coating onto heat
sensitive materials. This is accomplished by application of the
topcoat onto a heat dampening basecoat. The basecoat is applied as
a liquid--and allowed to chemically cross link to form a solid
rubber-like material. The primer is used to allow a 1/8" to 1" wide
transition of the plastic from the basecoat onto the substrate,
allowing the plastic to chemically bond to the substrate, while
providing complete encapsulation of the basecoat.
[0046] As an example, materials such as concrete and wood thermally
decompose and off-gas when thermoplastic is applied via flame
spray, arc-spray technology, or other thermal application
equipment, making it virtually impossible to coat with this
technique.
[0047] One solution to this problem is according to the following
technique:
[0048] 1) The substrate is cleaned of contamination and debris.
This is accomplished by mechanical (i.e. sand blasting, wire brush,
etc.), chemical means (acid wash, etc.), or any other known
technique for cleaning.
[0049] 2) The area to be coated is masked to appropriate dimensions
with conventional high temperature masking products. A second
masking is applied over the original masking--such that 1/8" to 1"
wide area of the substrate is covered, lapping into the area that
is to be coated.
[0050] 3) The heat dampening basecoat is mixed (resin+hardener) and
applied to the substrate. A thickness of 30-100 mils is preferred,
but other thicknesses can be employed depending on the
application.
[0051] 4) Once the basecoat is applied, and while still un-reacted
(up to 2-3 hours), an optional reinforcing layer may be added to
the system. One choice of material includes fiber (such as but not
limited to: glass fibers, thermoplastic fibers, thermosetting
plastic fibers, natural material such as cotton, carbon fibers,
metal fibers, and ceramic fibers). The fiber may be applied by
hand, spray, or other techniques recognized in the field. It is
preferred (but not necessary) to roll the fiber into the basecoat
with aid of hand held paint roller (or other applicable
techniques). Another option of reinforcement may include
reinforcing fabrics (such as but not limited to: glass fibers,
thermoplastic, fibers, thermosetting plastic fibers, natural
material such as cotton, carbon fibers, metal fibers, and ceramic
fibers). It is preferred (but not necessary) to roll the fabric
into the basecoat with aid of hand held paint roller (or other
applicable techniques). A third option includes a light flocking of
thermoplastic powder to be applied and allowed to chemically bond
to the basecoat (this flocking step is preferred for best
topcoat/basecoat adhesion, but is not necessary).
[0052] 5) Upon a minimum of 4 hours after the application of the
basecoat, the second applied mask is removed to yield 1/8" to 1" of
clean substrate (measured between basecoat and first masking
line).
[0053] 6) To the edges of the coating composite (1/8" to 1") where
the second mask has been removed, the alcohol/silane primer is
applied using any conventional applying technique (spray, brush,
etc.). The alcohol quickly evaporates leaving a thin layer of
primer deposited onto the substrate. The topcoat is now ready to
apply.
[0054] 7) Once the basecoat is ready, generally around a minimum of
4 hours, the topcoat may be applied via flame spray, arc-spray,
and/or thermal application equipment. Care is taken to limit the
amount of heat that is transferred to the silane-primed substrate.
A thickness of 10-100 mils is preferred, but other thicknesses can
be used. The coating is ready for service once the topcoat cools
and solidifies--and the masking is removed.
[0055] 8) The covered basecoat will continue to cure for several
days (3-4 weeks) to yield the final composite coating system.
Excellent chemical resistance, physical properties, adhesion,
serviceability, and corrosion resistance are realized with this
composite coating system.
[0056] Referring to FIG. 1, an example of a coating system is
designated by the reference numeral 10. The basecoat 1 is shown
applied to the substrate 3. Surrounding the periphery of the
basecoat 1 is the primer 5. FIG. 1 also shows that an optional
reinforcing layer 7 can be disposed on the basecoat if desired. The
reinforcing material 7 can be glass, a carbon fiber, polymeric
fibers, natural fibers, or metallic fibers.
[0057] The reinforcing layer 7 is covered with the topcoat 9, with
the topcoat extending beyond the edges of the basecoat so as to
encapsulate it.
EXAMPLES OF COMMERCIAL UTILITY OF COMPOSITE COATING SYSTEM
[0058] A few examples of where this novel system will find utility
in the market place include (but definitely not limited to):
[0059] 1) Coating of concrete (metal, ceramic, etc.) chemical
containment vessels, drainage pipes and troughs, and pads. (The
chemical resistant properties of the topcoat are superior to
conventional coatings).
[0060] 2) Coating of sewage, water, and gas lines.
[0061] 3) Coating of roofs (both new and refurbished) . . . homes,
commercial buildings, RV vehicles, trailers, outbuildings, sheds,
etc.
[0062] 4) Coating of wood materials (both new and refurbished). For
example, the system could be used to coat an existing wood fence,
wood patio deck, or wood decking in a horse trailer. The system
might also be used to coat wood piling and marine docks (coating is
forgiving, such that boat finish would be protected).
[0063] 5) Coating of heat sensitive, thin metals that would
normally warp by utilization of flame spray. For example, pick-up
beds.
[0064] 6) Coating of swimming pools and decks.
[0065] 7) Coating of power generators parts, windmills, dam
turbines, etc.
[0066] 8) Coating of amusement park equipment.
[0067] 9) Coating nuclear plant equipment (loading the topcoat and
basecoat with powder Tungsten, or other like materials, allows the
composite to shield against certain levels of radiation).
[0068] 10) Coating of space exploration equipment.
[0069] 11) Coating of car wash--pressure washing/steam cleaning
containment.
[0070] 12) Wood or metal play structure and decking (a soft
basecoat may prevent injuries).
[0071] 13) Coating of sunroom and green house floors.
[0072] 14) Coating of hard to adhere to materials. For example,
reasonable adhesion is obtained with the system applied to
Teflon.COPYRGT. (Teflon.COPYRGT. has very low surface energy, thus
making it difficult for most materials to adhere).
[0073] 15) Coating of hard to clean surfaces--such as wash down
rooms in food processing plants and various equipment in the food
industry.
[0074] 16) Coating of large structures such as bridges, boat docks,
buildings, etc.
[0075] 17) Coating of oil field equipment/offshore drilling
equipment.
[0076] 18) Coating laboratory floors--where a chemical resistant
coating is required. (Also, because the basecoat is rubbery, it is
ergo dynamically pleasing for people to stand on . . .
semiconductor industry, hospitals, chemical laboratories, and
production plants are targeted markets).
[0077] 19) The topcoat and basecoat can be formulated to be
electrically conductive by the addition of materials such as carbon
black, stainless steel powder, or silver coated glass spheres, etc.
This is useful for industries such as potato plants, where workers
are repeatedly shocked via static build-up on the potatoes, due to
the friction generated by the conveying equipment.
[0078] 20) Replacing/displacing current undercoating used on
vehicles.
[0079] 21) Various applications for the military. For example,
portable bridges, vehicles, coating the top-deck of Navy aircraft
carriers, etc.
[0080] 22) Coating of maritime equipment, i.e. ocean liners,
private boats, buoys, etc.
[0081] 23) Coating auto-garage floors, maintenance shops, machine
shops, etc.
[0082] 24) Coating earthen water sheds, such that held water does
not leak back into the ground.
[0083] 25) Coating earthen containment ponds, i.e. brine pits.
[0084] 26) Landscape ponds and water features. Commercial
anti-fungicides can be added to prevent barnacle and fungal growth
on coating.
[0085] 27) Coating of earthen/concrete/tile chemical containment
ponds.
[0086] 28) Engine rooms--ships, locomotive, power plant
[0087] 29) Coating equipment and support facilities for the
airplane industry.
[0088] 30) Repairing potholes in roads.
[0089] 31) Chemical hopper cars, chemical fill-station pads, etc.
for railroads.
[0090] 32) Coating of locker room floors
[0091] 33) Lining of waste disposal trucks and containers.
[0092] 34) Containment coating for plating and anodize lines
[0093] 35) Coating tile, glass, plastic, etc . . . virtually any
material.
[0094] Features of the composite coating system include (but
definitely not limited to):
[0095] 1) Correctly installed system adheres to virtually any
substrate and is resistant to a wide range of chemicals (-40 to 200
deg F.), where current coatings are not.
[0096] 2) Enhanced barrier properties to moisture, solvents,
chemical vapors, gases such as O.sub.2, and flavors, thereby
enhancing corrosion protection and performance of the coated
part.
[0097] 3) Enhanced physical properties of the coatings such as
modulus and tensile and heat deflection temperatures, due to the
reinforcing nature of the composite.
[0098] 4) Enhanced dimensional stability and reduced shrinkage of
the composite coating.
[0099] 5) System is able to bridge gaps and seems--surviving
expansion and contraction of substrate (i.e. concrete expansion
seems that thermally cycle through winter and summer). While the
final material may be used as a coating, the components of the
composite may also find industrial utility as a cast-able
elastomer, caulk, sealant, membrane, sponge, foam, adhesive,
potting and encapsulating compound, as well as other
rubber-fabricated materials. Some examples include:
electrical/electronic potting and encapsulation, asphalt extended
membranes (construction), waterproofing membranes, roofing,
mastics, highway sealants, architectural sealants, chemically
resistant coatings, adhesives, pond liners, athletic surfaces,
insulating glass sealants, rubber parts, military/aerospace
applications, reaction injection molding (RIM), and the automotive
industry.
[0100] Individual Basecoat Stand Alone Component
[0101] Besides the composite system for coating or other
applications, the individual system components also have utility on
their own as described below. The basecoat may be used as a
stand-alone coating for virtually any substrate. Excellent
adhesion, corrosion resistance, and bridging of gaps (such as
concrete seams) are realized. The basecoat may also find industrial
utility as a cast-able elastomer, caulk, sealant, membrane, sponge,
foam, adhesive, potting and encapsulating compound, as well as
other rubber-fabricated materials.
[0102] The basecoat may be applied by the following technique:
[0103] 1) The substrate is cleaned of contamination and debris.
This is accomplished by mechanical (i.e. sand blasting, wire brush,
etc.), chemical means (acid wash, etc.) or other conventional
cleaning technique.
[0104] 2) The area to be coated is masked to appropriate dimensions
with conventional masking products.
[0105] 3) The basecoat is applied to the substrate. After a certain
amount of time, e.g., 48 hours, the coating is ready for
service.
[0106] 4) The basecoat will continue to cure for several days (3-4
weeks) to yield the final cured properties of the coating.
Excellent physical properties, adhesion, and corrosion resistance
are realized with this coating.
[0107] The developed basecoat provides the following features:
[0108] 1) The material is a cost-effective plural component system
consisting of resin and a hardener. When the two materials are
thoroughly mixed together a coating window of approximately 2 hours
results, with a cured film resulting in approximately 24-48 hours.
By incorporation of appropriate catalysts and/or adjusting the
application temperature, this window can be shortened to a matter
of seconds (important for spray applied applications to vertical
surfaces).
[0109] 2) The material can be applied by conventional application
techniques including, but not limited to: brush applied, squeegee
applied, roller applied, trowel applied, and spray applied (the
material can be applied at ambient temperatures or warmed upwards
of the flashpoint of the resin).
[0110] 3) The material provides excellent adhesion to a variety of
materials. Item tested to date include: concrete, aluminum, steel,
glass, fiberglass, plastic, paper, wood, Teflon.COPYRGT., roofing
shingles, rubber, ceramic, leather, and synthetic foam.
[0111] 4) The basecoat material, when used as a stand-alone
coating, provides excellent adhesion, chemical resistance,
resiliency, impact resistance, flexibility, and elongation. It
successfully bridges gaps in areas such as concrete seems.
[0112] 5) Excellent long-term aging properties.
[0113] Thermoplastic Topcoat(s) (Stand-Alone)
[0114] The topcoat, when used as a stand-alone primer-less coating,
provides excellent adhesion and corrosion protection to metals and
glass. The coating may be applied via flame spray and other thermal
application equipment, and may be applied by conventional
powder-coating techniques (i.e. corona spray, tribostatic spray,
fluid-bed dipped, electrostatic fluid bed, flocked, etc.) There are
many items, found in industry, that lend themselves to be powder
coated: Patio furniture, garden tools, mail boxes,
appliances--dryer drums, front and side panels of ranges and
refrigerators, washer tops, water heaters and dishwasher racks,
automotive parts, closet shelving, automotive products--bumpers,
hubcaps, architectural pieces--aluminum window and door frames,
modular furniture decorative trim, door handles, metal fence, pipe,
carts, bicycles, lawn mowers, filing cabinets, glass, medical
equipment, chemical plants, sporting goods, light poles, bike
racks, brackets, etc.
[0115] The chemistry for the general topcoat formulation (based on
polyethylene), for the composite coating system, is provided
below). Other topcoat resin chemistries and additives may be
utilized to provide for different end uses, such as--more abrasion
resistance, increased hardness, different chemical resistance
profiles, different service temperatures, etc. Coatings can include
(but not limited to) these plausible thermoplastic resin systems:
ethylene-vinyl acetate, polypropylene, ethylene-methyl acrylate EMA
and ethylene-methyl methacrylate EMM/polyethylene copolymers,
polyethylene, polyethylene acid terpolymers, polyethylene ionomers,
polyamide co- and ter- polymers, thermoplastic elastomers (TPE's),
acrylonitrile-butadiene-styrene, acrylonitrile halogenated
polyethylene, acrylonitrile halogenated styrene,
acrylic-styrene-acryonitrile, cellulose acetate, cellulose
acetate-butyrate, cellulose acetate-propionate, halogenated
polyethylene, halogenated polyvinyl chloride,
polymonochlorotrifluoroethylene, diallyl phthalate, ethyl
cellulose, ethylene-chlorotrifluroethylene, ethylene-propylene,
tetrafluoroethlyene-hexafluoropropylene-vinylidene fluoride
ter-polymer, EVOH, PEBA, ethylene-tetraflurethylene, fluorinated
ethylene-propylene, high-impact polystyrene, vinyl modified epoxy,
liquid crystal polymer, methacrylateo-butadiene-styrene, polyamide,
polyamide-imide, polyacrylonitrile, polybutylene, polybutylene
terephthalate, polycarbonate, polychlorotrifluoroethylene,
polyphenylene ether copolymer, polyetherether ketone, polyphenylene
ether homopolymer, polyetherimide, polyethylene oxide,
polyethersulphone, phenly-formaldeahyde, perfluoroalkoxy,
polyimide, polyisobutylene, polyisoethylene, paramethylstyrene,
polymethylpentene, polyphenylene oxide, polyphenylene sulfide,
polystyrene, polytetrafluoroethylene, polyurethane (polyester and
polyether backbone), polyvinyl chloride, polyvinylidene fluoride,
polyvinyl fluoride, styrene-acrylonitrile, styrene maleic
anhydride, polytetra fluorethylene, urea-formaldehyde, vinyl
acetate-ethylene, polyacetal, polyacrylic, polyalkyd, polyallylic
esters or allyis, cellulosic esters, halogenated polyalkylene
ether, cyanate/cyanamide polymers, halogenated epoxies,
cycloaliphatic epoxys, epoxyimide polymers, polyester polymers,
polyether polymers, and polyphenylene.
[0116] In addition, modifications to the above listed material,
including silane grafting, maleic anhydride grafting, acrylic acid
grafting, and grafting of any functional group containing an active
hydrogen may be used. For example, polyethylene may be modified
(peroxide grafting) to include silane, maleic anhydride, acrylic
acid, or virtually any functional group containing an active
hydrogen. Also, co- and poly-polymers utilizing the above resins
and/or modified resins may be used.
[0117] Furthermore, any virtual array of blends utilizing the
aforementioned thermoplastic resins, modified resins, or co- and
poly-polymers of above listed resins may be used.
[0118] All coatings can be made available in virtually an unlimited
array of color selections and finishes. From fluorescent to
jet-black; from smooth-high gloss, dimple and pinhole free
surface-to wrinkled textures; as well as colors and finishes
between these extremes.
[0119] Thermoplastic Powder Coatings Are Applied By Various
Methods:
[0120] Coating-of a part generally requires two steps (but not
necessarily in this order): 1. deposition of the powder, and 2.
Oven (heat) to flow the powder into a film. A spray booth is very
desirable, and in some instances necessary. The booth keeps the
powder overspray contained so that it is not a hazard (high
concentrations of air-borne powder can be an explosion hazard).
Other hazards that are curbed include breathing of the dust. The
booth also promotes good "industrial hygiene." Also, by use of a
spray booth, powder overspray may be reclaimed for reuse.
[0121] FIG. 2 shows one of the simplest methods in which to coat
parts. A fluidized-bed canister is filled with powder. A small
amount of air is introduced into the bottom of the canister and
rises through a porous fluidizing board. This "fluffs" the powder
and causes it to behave like a liquid, or to become "fluidized."
The part is preheated and dipped into the fluidized bed, and
treated afterwards if necessary with additional heating for the
proper finish.
[0122] FIGS. 3 and 4 illustrate electrostatic spray methods. As the
powder paint cloud gently leaves the spray gun, it is charged with
static electricity to attract the powder paint to the part being
coated. The part is then placed in an oven (typically
250-600.degree. F.) and allowed to melt and flow to a "proper
durable and beautiful finish." In FIG. 3, the part can be
preheated.
[0123] FIGS. 5 and 6 show electrostatic fluid-bed methods. In the
electrostatic fluidized bed process, powder particles are aerated
in a fluidizing chamber. The powder is electrostatically charged by
ionized air, which passes through a porous plate at the base of the
fluidized bed. The part is preheated in FIG. 5 prior to passing
through the cloud of particles, whereas FIG. 6 merely conveys the
part through the cloud, and then subjects the part to post heating
if necessary. The charged powder particles, which repel one
another, rise above the fluidizing bed, forming a cloud of charged
particles. A hood above the fluidizing bed prevents powder from
entering the plant atmosphere. When a grounded part is placed in
the cloud or conveyed through it, the charged particles are
attracted to the part. The particles are more attracted to exposed
areas than to those already coated, which provides a uniform
coating on the part. Coating thickness is largely controlled by
adjusting the applied voltage to the charging media and the amount
of time the part is within the cloud. Because of the high voltage
capability of the charging media, sufficiently great potential
exists between the powder coating and most substrates, which
permits even natural insulators to be coated. The unique air
ionization process charges the powder without allowing the
operator, the part or the powder to come in contact with the
charging media.
[0124] FIGS. 7 and 8 show tribostatic spray methods. Tribostatic is
the work used to describe a static charge that builds when two
dissimilar materials are rubbed together--This is a cost effective
method of applying coatings. It is usually the best method for
applying a second coat over an existing finish. FIG. 7 shows the
method with a preheating step, with FIG. 8 showing just the powder
application step and the post flow step.
[0125] FIG. 9 shows a flocking spray method. This method deposits
an aerosol of powder to a hot substrate. The powder hits the hot
part and partially melts to the substrate. The part is then placed
back in the oven for the post flow
[0126] FIG. 10 shows a flame spray and arc-spray technique. The
thermoplastic powder is siphoned into a propane/compressed
air-fueled flame. The flame melts the powder and deposits it onto
the substrate.
[0127] The developed topcoat provides the following features:
[0128] a) Superior corrosion protection and chemical resistance
(generally resistant to most acids, bases, oils and solvents).
[0129] b) Exceptional adhesion, including when applied over a
basecoat.
[0130] c) Repairable.
[0131] d) Flexible.
[0132] e) Custom colors.
[0133] f) Exceptional impact strength and chip resistance.
[0134] g) Finish can be smooth or textured.
[0135] h) Abrasion resistant.
[0136] i) Environmentally friendly, 100% solids, little or no
VOC's, solvents, cross-linking agents and no heavy metals.
[0137] j) Potable water and direct food contact formulations
available.
[0138] k) Excellent UV-stability.
[0139] l) Physicals such as hardness, gloss, etc. may be
adjusted.
[0140] m) Good operating temperature properties (-40 to 200
deg.degree. F.).
[0141] n) Low smoke development when in fire.
[0142] o) No cure time--coating may be put in service when
cooled.
[0143] p) Safe for disposal in public landfill.
[0144] q) No shelf life or pot life restrictions.
[0145] r) Electrically insulating to electroconductive formulations
possible.
[0146] s) There are no runs or drips as there is with liquid
coatings.
[0147] t) Over spray is reused
[0148] u) Special effects, additives, and performance requirements
can be readily formulated
[0149] Primer/Topcoat (Stand-Alone)
[0150] The alcohol/silane primer is used to increase adhesion of
the topcoat to substrates, particularly difficult to adhere to
substrates (anodized metals, stainless steel, etc). The primer is
deposited, solvent is allowed to flash (evaporate), and the part is
then coated according to the examples given above. This ambient
applied, cost effective, primer increases the adhesion of the
thermoplastic topcoat to substrates.
[0151] Description of Preferred Manufacture, Materials, and
Composition Ranges for Basecoat:
[0152] Manufacture--Basecoat:
[0153] 1) One preferred basecoat formula (based on weight % of
final formulation) is:
1 44.5% Petroleum Asphalt (U.S. Oil and Refining Co. PG 52-28)
44.5% 1,3-butadiene, homopolymer, hydroxy-terminated (Elf Atochem
North America, Inc. RT45HTLO) 9.0% 1,4 butanediol diglycidyl ether
(Shell Heloxy Modifier 67) 0.5% Acrylic Oligomer (Estron Chemical,
Inc. Resiflow LV-67) 0.5% 2,2'-Methylenebis
(4-methyl-6-tertiarybutyl phenol) (Cytec Cyanox 2246) 1.0%
Amorphous Fumed Silica (Degussa-Huls Corp. Aerosil 200)
[0154] 2) Blending and one preferred manufacturing method for the
basecoat formula:
[0155] The petroleum asphalt is heated to 140-360 deg F. and
removed from the heat source. To this warm material the
hydroxy-terminated 1,3-butadiene homopolymer is added with the aid
of mechanical stirring. Next, the remainder of ingredients are
added and the resin is mixed with mechanical stirring until a
uniform dispersion is obtained. The resin is allowed to cool
completely to room temperature and packaged for resale. It is
preferred to blend all components under gaseous nitrogen or vacuum,
such that oxidative degradation of the resin is curbed.
[0156] 3) To this blended resin a hardener, e.g., a modified
diphenylmethane diisocyanate)--is added at 1:9 resin by wt.
(corresponding to a NCO/OH ratio of approximately 1.10). Of course,
other hardeners may be used as would be recognized by those skilled
in the art.
[0157] 4) Description of broad ranges of ingredients (more narrow
ranges are found in the claims):
[0158] Petroleum Asphalt
[0159] The asphalt is incorporated into the formulation to provide
tack, and to extend the hydroxy-terminated, 1,3-butadiene
homopolymer (cost effective). Lower loadings of asphalt will
produce a harder, less elastic material--as well as reducing the
viscosity of the blended resin system. Higher loadings of the
asphalt will produce a more viscous resin, which cures to yield a
softer material that has more residual tack and elasticity. A broad
range of 10-90%, final formulation is obtainable. Materials such as
petroleum asphalt grade PG 64-22 are noted to increase the tensile
properties by upwards of 20%.
[0160] In addition, other petroleum based, hydrocarbon crudes (of
approximately same molecular weight) may substitute. Petroleum
hydrocarbon oil may also be used in conjunction with the asphalt,
as an extender and diluent. Other thermoplastic and
non-thermoplastic resins, and other thermoplastic and
non-thermoplastic resins with select fillers (such as hollow glass
spheres, for example), may be added at a range of 10-90% to modify
end physical (such as topcoat/basecoat inter-adhesion).
[0161] A list of generally compatible extenders that may substitute
include: dioctyl phthalate, diundecyl phthalate, tricresyl
phosphate, halogenated paraffin, aromatic process oil, naphthenic
process oil, alkyl naphthalenes, asphalt, coal tar, linseed oil,
tung oil, detergent alkylate, and others as recognized by those
skilled in the art.
[0162] 1,3-butadiene, Homopolymer, Hydroxy-Terminated
[0163] The hydroxy-terminated, 1,3-butadiene homopolymer is
incorporated into the formulation to provide resiliency and
crosslinkability (through the hydroxyl groups on the terminus of
the butadiene polymer). Increasing the loading of this ingredient
(and the corresponding amount of hardener) will result in a harder
material that has reduced elasticity. Decreasing the ingredient
(and the corresponding amount of hardener) will result in a softer
mastic with greater elongation properties. A range of 10-90%, final
formulation is obtainable. In addition, other functionalized
polymers, with either aromatic or aliphatic type backbones may be
substituted (also copolymers and modified homo/co polymers). The
functional groups- may include: alkyd, hydroxy, carboxy, amine, and
virtually any other compound containing an active hydrogen.
[0164] 1,4 Butanediol Diglycidyl Ether
[0165] The diglycidyl ether reactive diluent is used to reduce the
viscosity of the resin and cross-link with the hardener. Increasing
the loading of this ingredient (and the corresponding amount of
hardener) will result in a harder material that has reduced
elasticity. Decreasing the ingredient (and the corresponding amount
of hardener) will result in a softer mastic with greater elongation
properties, although the viscosity increases dramatically. This
material provides for better topcoat-basecoat adhesion. A range of
0.1 - 30%, final formulation is obtainable. In addition, other
functionalized polymers, with either aromatic or aliphatic type
backbones may be substituted. The functional groups may include:
alkyd, hydroxy, carboxy, amine, and virtually any other compound
containing an active hydrogen. The polymers may have a range of
functionality/molecule. Harder, less flexible films are expected as
functionality increases. Also, viscosity may range from 1 cP
upwards of 5000 cP. It, is also plausible to consider non-reactive
diluents, such as plasticizers, oils, etc. Other glycilyl reactive
diluents can be used as well. As another example, a mono-functional
glycidyl ether diluent results in a very soft "gel" mastic, which
enhances the system where foot traffic and ergonomics are
important.
[0166] Surface Modifiers (Surfactants)
[0167] The acrylic is used to improve flow, eliminate air
entrapment, orange peel, pinholes, craters, and other surface
imperfections. This ingredient improves the flexibility of the
coating and provides for better topcoat-basecoat adhesion. A range
of 0.1 to 5%, final formulation is obtainable. Other acrylic
(supplied as both liquid or on solid carrier particles) and
non-acrylic modifiers yield virtually the same results (i.e.,
benzoin and Acetylenic diol's). Anti-foam agents, such as silicone
oils may be used, when the basecoat is used as a stand alone
coating. Ranges are from 0.1 to 5%, final formulation. Other
material, typically considered to be utilized as surfactants by
formulators in the art, may be utilized.
[0168] 2,2'-Methylenebis (4-methyl-6-tertiarybutyl phenol)
[0169] This material is used as an anti-oxidant to protect the
cured resin from thermal decomposition, upon exposure to the flame
applied topcoat. Higher loading levels show improvement in thermal
stability, where lower levels decrease the thermal stability of the
basecoat. Other phenol and "Non-phenol" type anti-oxidants
generally give the same results. An example includes thioester
antioxidants. Loadings range from 0.01 to 5%, final
formulation.
[0170] Light Stabilizers
[0171] If the basecoat is to be used as a stand-alone coating, it
may be necessary to stabilize for UV exposure. Light stabilizers
that may be incorporated include: benzophenone, benzotriazole,
triazine, benzoxazinone, hindered amines, and hindered benzoate.
Loadings may range from 0.01% to 5%, final formulation.
[0172] Amorphous Fumed Silica
[0173] This material is used as a thickening agent/anti-sag agent.
It prevents phase separation of material when stored for long
periods of time. Decreasing the loading of this material into the
resin decreases the viscosity. Increasing the loading of this
material (up to 10%) increases the viscosity, such that the resin
is trowel-able, to apply to vertical surfaces. The addition of the
silica does not significantly affect the performance of the
basecoat. The material may be loaded at 0.01 to 10%, final
formulation. Other thickening agents that may substitute include,
but are not limited to the materials listed in the filler portion
of this disclosure. Loadings are anticipated to be 0.1 to 25%,
final formulation.
[0174] Modified Diphenylmethane Diisocyanate
[0175] The MDI is used to cross link with the hydroxy terminated
polybutadiene, diglycidyl ether reactive diluent, and active
hydrogens contained in the petroleum asphalt. It is incorporated
according to stoichiometric equivalents. Increasing the amount of
hardener results in a harder film, and reducing the amount of
hardener results in a softer film. By choosing the correct MDI (or
other poly-functional isocyanates) variable such as pot life and
end physicals may be adjusted. Other multi-functional isocyanates
may also be used including: aliphatic, aromatic, TDI, etc. Also,
diamines and other hardeners recognized by those skilled in the art
may substitute.
[0176] Catalysts
[0177] Catalysts may be used to accelerate the crosslinking of the
basecoat. Three candidates have been found to date: 1) dibutyltin
dilaurate, 2) aminopropyltriethoxysilane, and 3)
triethylenetetramine. In general, most amines will catalyze the
reaction, as well as, the tin dilaurate. Many catalysts, known in
the urethane formulation art, may be utilized. Loadings are
typically at 0.0001 to 5%, final formulation.
[0178] Polyols
[0179] Physical properties of the system can be improved by the
addition of auxiliary polyols to the formulation. A wide variety of
short chain diols (i.e., polyether and polyester backbone) may be
employed, however, Voranol 220-530 (phenyl diisopropanolamine) was
found to be the most effective. The use of a short chain diol in
conjunction with the required additional isocyanate increases the
urethane concentration in the final polymer backbone. This
combination leads to increased hydrogen bonding between polymer
chains and thus higher strength properties in the cured elastomer.
The same effects can be noted when short chain diamines or mixed
alcohol diamines are employed as auxiliary reactants with the
system.
[0180] Fillers
[0181] Fillers common the industry (but not limited to) include:
aluminum oxide, calcium carbonates, dolomite, calcium sulfate,
silicates, glass spheres (solid and hollow), asbestos, talk,
kaolin, mica, feldspar and nepheline syenite, wollastonite,
silicate spheres, silica, natural silicas, synthenic silicas,
adhesion promoters (silanes, titanate, zirconate, and aluminate
coupling agents), molybdenum disulfide, polytetrafluoroethylene,
barium sulfate, metals and metal oxides, aluminum hydroxide,
carbon, fibers (natural and synthetic--basalt, carbon polyamide,
glass, boron, ceramic), electrically conducting fillers (stainless
steel, carbon, carbon fibers, silver coated glass particles), radar
absorbing materials, radiation shielding/EMI shielding (Tungsten
powder), magnetic additives (strontium ferrite and ceramics),
rubber (virgin and re-processed), and sound dampening materials may
be incorporated into the resin to dilute the cost, and/or alter
physical properties. Loadings for fillers may range from 0.01 to
75%, final formulation. Typically increased loadings of fillers
will cause the viscosity of the final formulation to increase.
[0182] Thermal Conductivity Agents
[0183] Zinc Oxide (and other materials such as ceramics), in
addition to reinforcement, also provides resilience and heat
conductivity. This is an important filler, where enhanced thermal
conductivity is of concern. Loadings are typically at 0.1 to 75%,
final formulation. Anti-thermal conductive materials (glass and
ceramic) may also be used for the opposite effect. Loadings are at
0.1 to 75%, final formulation.
[0184] Drying Agents
[0185] Alkali-metal alumino-silicate materials may be used as a
molecular sieve adsorbent for static dehydration in the
formulation, increasing shelf life of the product. This material is
also useful when the removal of water is of interest; i.e.,
One-Step mechanism, as described below. PTSI (para-Toluenesulfonyl
Isocyanate) reacts toward active hydrogen atoms, making it ideal
for scavenging water and other isocyanate reactive groups (such as
free acid in powdered aluminum alkanoates and active hydrogen
present in carbon black pigments). This prevents the thickening of
the formulation during storage. This material is especially useful
for One-Step mechanisms. Loadings are typically 13 grams/gram of
water.
[0186] Flame Retardants
[0187] Flame retardants for the formulation are plentiful. Some of
these include (but are not limited to): halogen liberating flame
retardants, antimony oxide, phosphorous containing agents, modified
silicones, alumina trihydrate, magnesium hydroxide, organically
modified montmorillonite clay, expandable graphite, boric oxide,
zinc borate, etc. Loadings are typically 0.1 to 60%, final
weight.
[0188] Corrosion Inhibitors
[0189] Corrosion protection agents may include polyaniline, amino
tri (methylene-phosphonic acid)--(ATMP), ammonium benzoate, sodium
nitrite, 2-benzothiazolylthio-succinic acid (MBTS), primary,
secondary, and tertiary aliphatic amines, aliphatic diamines,
cycloaliphatic and aromatic amines, polymethylimines, long-chain
ethanolamines, imidazolines, amine salts of carbonic, carbamic,
acetic, benzoic, oleic, nitrous, and chromic acids, acetylenic
alcohols, lauric alcohol, alkyl chromates, organic esters of
nitrous acid, organic esters of phthalic acid, organic esters of
carbonic acid, nitronaphthalene, nitrobenzene, etc. The anticipated
loadings may range from 0.1 to 50%, final formulation.
[0190] Antistatic Agents
[0191] Antistatic agents prevent dust attraction, discharge process
that may damage the product (i.e., packaging and handling of
electronic chips), and curbing spark discharge that can produce
serious accidents. Additives in loadings ranging between 0.1 to
50%, final formulation include:
[0192] a) Cationic compounds (best effect in polar substrates),
generally consisting of a voluminous cation which often contains a
long alkyl residue (i.e., quaternary ammonium, phosphonium or
sulfonium salt, etc.). In most cases, the anion is the chloride,
methosulfate or nitrate originating from the quaternization
process.
[0193] b) Anionic compounds, mostly an alkyl sulfonate, sulfate or
phosphate, a dithiocarbamate or carboxylate, alkali metals,
etc.
[0194] c) Nonionic compounds, uncharged surface-active molecules
including: polyethylene glycol esters or ethers, fatty acid esters
or ethanolamides, mono- or diglycerides or ethoxylated fatty
amines, etc.
[0195] Biostabilizers
[0196] These materials are often used as package preservative, can
corrosion inhibitor, mold inhibitor (fungicide), and tannin stain
blocking agent. Several commercially available agents are
available, which typically base their chemistry on organic
materials (i.e., Buckman Laboratories). Other materials may include
zinc oxide, copper oxides, etc. The anticipated loadings range
between about 0.1 to 10%, final formulation.
[0197] Chemical Blowing Agents
[0198] Chemical blowing agents, when incorporated into the
basecoat, release small amounts of gas--resulting in a foamed
material. Examples include (but are not limited to) a mixture of
sodium bicarbonate and acetic acid, chloro-fluorocarbons, etc. This
material typically ranges between about 0.1 to 10%, final
formulation.
[0199] Scent Additives
[0200] Scent additives (such as Stanley S. Schoenmann's products)
provide an array of different fragrances that may be incorporated
into the formulation. Loadings range between about 0.1 to 25%,
final formulation.
[0201] Bittering Agents and Pepper
[0202] Bitter agents such as ground buffalo gourd may be
incorporated into the coating to prevent damage by livestock (via
oral degradation of the coating). Other ingredients include cyanine
pepper powder, etc. Loadings are typically 0.1 to 25%, final
formulation.
[0203] Pigments/Effects
[0204] Carbon black will cause tensile, modulus, tear, and hardness
to increase, as the carbon loading is increased. In addition,
carbon black gives the formulation the color of black. Typical
loadings range from 0.1 to 40%, final formulation. Many other
organic and inorganic pigments may be used. Specialty pigments,
such as pearl and glow-in-dark may be incorporated.
[0205] Fluorescent Whiting Agents
[0206] Materials such as
2,2'-(2,5-thiophenediyl)bis[5-tert-butylbenzoxazo- le] are often
used to provide brighter looking colors. This material may be
incorporated into the basecoat as a mechanism in which to detect
pinholes and defects in the topcoat. Typical loadings are 0.1 to
10%, final formulation. The method of detecting pinholes and
defects in the topcoat is as follows: 1) the system is correctly
installed, and 2) a blacklight is scanned over the
topcoat--pinholes and defects (thin spots) are illuminated (by the
fluorescent whiting agent in the basecoat), thus detected. Once
detected, additional topcoat may be applied to seal the defect
areas.
[0207] Lubricants
[0208] Incorporation of lubricants may provide useful properties to
the system. Typical lubricants include: fatty alcohols ant their
dicarboxylic acid esters, fatty acid esters of glycerol and other
short chain alcohols, fatty acids, fatty acid amides, metallic
soaps, oligomeric fatty acid esters (fatty acid complex esters),
fatty acid esters of long-chain alcohols, montanic acid, esters and
soaps, polar polyethylene waxes and their derivatives, nonpolar
polyolefin waxes, natural and synthetic paraffin waxes,
fluoropolymers, and molybdenum disulfide.
[0209] Plasticizers
[0210] Typical plasticizers that may be used include phthalates,
monocarboxylic acid esters, acetates, propionates and butyrates,
esters of ethylbutyric and ethylhexanoic acid, glycolic acid
esters, benzoic acid esters, epoxidized fatty acid esters,
plasticizers based on phthalic acids, aliphatic dicarboxylic acid
esters, phosphates, polyester plasticizers, trimellitic acid
esters, citric acid esters, sulfonic acid esters and sulfamides,
alcohols, ethers and ketones, abietic acid esters, polymerizable
plasticizers, hydrocarbons and halogenated hydrocarbons. Ranges are
from 0.1 to 25%, final weight.
[0211] 5. An alternative one-step mechanism is as follows.
[0212] This basecoat material may also be formulated into a
one-step urethane reaction.
[0213] For this manufacturing process, the components of the
desired formulation are weighed; i.e., hydroxy-terminated,
1,3-butadiene homopolymer resin, petroleum asphalt, filler(s),
extender oil(s), anti-oxidants, plasticizers, and catalyst. For
example, one preferred basecoat formula (based on weight % of final
formulation) is:
2 44.5% Petroleum Asphalt (U.S. Oil and Refining Co. PG 52-28)
44.5% 1,3-butadiene, homopolymer, hydroxy-terminated (Elf Atochem
North America, Inc. RT45HTLO) 9.0% 1,4 butanediol diglycidyl ether
(Shell Heloxy Modifier 67) 0.5% Acrylic Oligomer (Estron Chemical,
Inc. Resiflow LV-67) 0.5% 2,2'-Methylenebis
(4-methyl-6-tertiarybutyl phenol) (Cytec Cyanox 2246) 1.0%
Amorphous Fumed Silica (Degussa-Huls Corp. Aerosil 200)
[0214] The materials are charge to a suitable mixing device and
allowed to mix until the ingredients are well dispersed. This
"master-batch" may be degassed under vacuum--it may also be
necessary to dry fillers at elevated temperatures to remove
moisture. If degassing is not possible, a gaseous nitrogen blanket
should be used. The petroleum asphalt is heated under dry nitrogen
to 140-360 deg F. and removed from the heat source. To this warm
material the hydroxy-terminated 1,3-butadiene homopolymer is added
with the aid of mechanical stirring. Next, the remainder of
ingredients are added and the resin is mixed with mechanical
stirring until a uniform dispersion is obtained. The resin is
allowed to cool completely to room temperature. Next, the
calculated amount of di- or polyisocyanate is added to the mixture
to give the desired NCO/OH ratio. Optimum properties are usually
obtained at NCO/OH ratios between 1.0 and 1.2. For our system
modified diphenylmethane diisocyanate is added at 1:9 resin by wt.
(corresponding to a NCO/OH ratio of approximately 1.10). Of course,
other hardeners may be used as would be recognized by those skilled
in the art.
[0215] The completed formulation is mixed until homogeneous (the
reaction of the isocyanate with hydroxyl groups will generate
heat--a cooling jacket may be required on the mixing vessel). The
finished material is then pumped into suitable containers (care is
taken not to expose formulation to atmospheric moisture).
[0216] The system, prepared as described above, is applied as a one
step curing basecoat. The applied material reacts with atmospheric
water to give urea structures, or can form allophanate crosslinks
(especially at elevated temperatures). Upon proper cure (longer
cure to be anticipated compared to A+B mixture) no differences in
properties should be noted, as compared to the A+B mixture.
Potlifes and physicals can be tuned for this system by engineering
the formulation properly. All of the above auxiliary ingredients
may be incorporated into this system, as outlined above.
[0217] Alternatively, isocyanate functional silanes may be utilized
in place of the poly-functional isocyanate. For example, one
preferred basecoat formula (based on weight % of final formulation)
is:
3 44.5% Petroleum Asphalt (U.S. Oil and Refining Co. PG 52-28)
44.5% 1,3-butadiene, homopolymer, hydroxy-terminated (Elf Atochem
North America, Inc. RT45HTLO) 9.0% 1,4 butanediol diglycidyl ether
(Shell Heloxy Modifier 67) 0.5% Acrylic Oligomer (Estron Chemical,
Inc. Resiflow LV-67) 0.5% 2,2'-Methylenebis
(4-methyl-6-tertiarybutyl phenol) (Cytec Cyanox 2246) 1.0%
Amorphous Fumed Silica (Degussa-Huls Corp. Aerosil 200)
[0218] The materials are charge to a suitable mixing device and
allowed to mix until the ingredients are well dispersed. This
"master-batch" may be degassed under vacuum--it may also be
necessary to dry fillers at elevated temperatures to remove
moisture. If degassing is not possible, a gaseous nitrogen blanket
should be used. The petroleum asphalt is heated under dry nitrogen
to 140-360 deg F. and removed from the heat source. To this warm
material the hydroxy-terminated 1,3-butadiene homopolymer is added
with the aid of mechanical stirring. Next, the remainder of
ingredients are added and the resin is mixed with mechanical
stirring until a uniform dispersion is obtained. The resin is
allowed to cool completely to room temperature. Next, the
calculated amount of isocyanate functional silane is added to the
mixture to give the desired NCO/OH ratio. Optimum properties are
usually obtained at NCO/OH ratios between 1.0 and 1.2.
[0219] The completed formulation is mixed until homogeneous (the
reaction of the isocyanate with hydroxyl groups will generate
heat--a cooling jacket may be required on the mixing vessel). The
finished material is then pumped into suitable containers (care is
taken not to expose formulation to atmospheric moisture).
[0220] This prepared system is applied as a one step curing
basecoat. The applied material crosslinks (cures) when exposed to
moisture.
[0221] 6. An alternative two-step mechanism, utilizing different
crosslinking mechanisms.
[0222] In many conventional applications, it is desirable or
essential to utilize a two-step reaction sequence, wherein an
isocyanate terminated prepolymer (quasi-pre-polymer) is first
formed and subsequently converted to a high molecular weight cured
elastomer by further reaction with glycols, diamines, or other
chain extending agents.
[0223] For example, one preferred basecoat formula (based on weight
% of final formulation) is:
4 44.0% Petroleum Asphalt (U.S. Oil and Refining Co. PG 52-28)
44.0% 1,3-butadiene, homopolymer, hydroxy-terminated--conve- rted
to a prepolymer (NCO/OH ratio = 1.1) 1.0% Benzoyl chloride 9.0% 1,4
butanediol diglycidyl ether--converted to a prepolymer (NCO/OH
ratio = 1.1) 0.5% Acrylic Oligomer (Estron Chemical, Inc. Resiflow
LV-67) 0.5% 2,2'-Methylenebis (4-methyl-6-tertiarybutyl phenol)
(Cytec Cyanox 2246) 1.0% Amorphous Fumed Silica (Degussa-Huls Corp.
Aerosil 200)
[0224] The petroleum asphalt (100 gm), 1,3-butadiene, homopolymer,
hydroxy-terminated (100 gm) and 1,4 butanediol diglycidyl ether
(20.5 gm) was charged into a five-gallon working capacity 316
stainless steel jacketed autoclave equipped with a mechanical
stirrer, thermowell, charging port, vacuum and nitrogen lines, and
a bottom exit port. The autoclave was sealed, stirrer turned on,
and evacuated to 30 mm mercury.
[0225] The vessel was then heated to 225 deg F., via heated oil
passed through the vessel jacket. Approximately 3 hours was
required to heat the charge. The vessel contents were degasses and
stirred for and additional 30 minutes at 10 mm mercury. The
contents were then cooled to 100 deg F.
[0226] The pressure was adjusted to 60 mm mercury and benzoyl
chloride added. The addition of benzoyl chloride was found to
greatly enhance the stability of the prepolymer. After stirring for
10 minutes, the diisocyanate with an equivalent weight of 136
(corresponding to a necessary 34 gm load) was added over a 5 minute
interval. The exotherm was found to increase the temperature by 20
deg F.
[0227] The vessel contents were heated to 150 deg F. and allowed to
stir for 1 hour. The remainder of the ingredients were then added.
The mixture was allowed to stir for a two hour period at 60 mm
mercury. The finished material was then transferred into suitable
containers--under dry nitrogen (care is taken not to expose
formulation to atmospheric moisture).
[0228] This prepolymer material may then be cured by use of a
variety of chain-extending diols or diamines. We chose a polyether
polyol (Dow Voranol 220-530). A weight ratio of 1:5 prepolymer was
found to give good result.
[0229] Isocyanate prepolymers are widely used for producing high
performance elastomers of castable, millable, and moldable types.
Other applications include foams, and one and two component
coatings, caulks, sealants, etc.
[0230] Description of Preferred Manufacture, Materials, and
Composition Ranges for Topcoat
[0231] Manufacture--Topcoat:
[0232] 1) Disclosure of one preferred topcoat formula (based on
weight % of final formulation):
5 41.49% Acid-modified ethylene terpolymer with temperature stable
ester and high acidic functionality (Dupont Bynel CXA 2022) 41.49%
Polyethylene/methacrylic acid copolymer (Dupont Nucrel 599) 10.0%
Polyethylene/methacrylic acid copolymer partially neutralized with
sodium (Dupont Surlyn 8670) 5.0% Grey pigment polymeric dispersion
(MA Hanna product #10080332) 0.5% Antioxidant (Ciba Irgonox 1010)
0.5% Benzotriazole light stabilizer (Fairmount Chemical Co. Mixxim
BB/100) 1.0% Acrylic Oligomer (Estron Chemical, Inc. Resiflow
LV-67) 0.02% Amorphous Fumed Silica (Degussa-Huls Corp. Aerosil
200) (post-additive)
[0233] 2) One mode of blending and manufacturing of topcoat
formula:
[0234] All materials are mechanically pre-blended. This blended
material is then passed through a 1:24 single screw plastic
extruder at a temperature of 240 -280 deg F. The extruder melts and
disperses the ingredients. The material exits the extruder as a
molten strand and is cooled and re-solidified in a water trough.
The solidified strand is then pelletized.
[0235] The processed pellets are then cryogenically ground to a
powder, screened to the correct particle size, and then dried and
packaged. The powder is the finished product.
[0236] Cryogenic grinding of the material will yield particles of a
specific size. For our application, -40mesh seems to work the best
for thermal application equipment (-80 for powder coating grade). A
range of -35 to -500 mesh may find utility in the marketplace.
[0237] To the ground powder, fumed silica may be incorporated at up
to 5.0 % by weight to aid in dry flow-ability of the powder.
[0238] Other methods of blending can also be employed to produce
the powder product.
[0239] 3) Description of range of ingredients:
[0240] All weight % of materials are optimized for this system.
Like products may substitute for the quoted ingredients. Percentage
of materials will produce different materials with different
physicals. Different pigments may require different loadings.
[0241] Acid-Modified Ethylene Terpolymer With Temperature Stable
Ester and High Acidic Functionality (Dupont Bynel CXA 2022+ Like
Products)
[0242] This material is found to maximize different polymer
compatibility in the system. This material also aids in adhesion of
the blended formulation and filler compatibility. Properties such
as impact resistance and cold weather impact are improved with
utilization of the material. Other thermoplastic olefins,
functionalized or non-functionalized, co, ter polymers, other
thermoplastic and non-thermoplastic resins may be added at a range
of 10-90% to modify end physicals. In addition, other
functionalized polymers, with either aromatic or aliphatic type
backbones may be substituted. The functional groups may include:
alkyd, hydroxy, carboxy, amine, and virtually any other compound
containing an active hydrogen. Melt flow ranges are from 1 to 1000.
Loadings may range from 5 to 95%, final formulation.
[0243] Polyethylene/Methacrylic Acid Copolymer (Dupont Nucrel, Dow
Primacor+Like Products)
[0244] This material is used for adhesion, and filler
compatibility. Chemical resistance is also realized with this
resin. Loadings may range from 5 to 95%, final formulation. Other
thermoplastic olefins, functionalized or non-functionalized, co,
ter polymers, other thermoplastic and non-thermoplastic resins may
be added at a range of 10-90% to modify end physicals. Melt flow
ranges are from 1 to 1000. Loadings may range from 5 to 95%, final
formulation.
[0245] Polyethylene/Methacrylic Acid Copolymer--Ionomer (Dupont
Surlyn, Exxon Lotek+Like Products)
[0246] This resin adds hardness, tensile, and mar resistance to the
formulation. Other thermoplastic olefins, functionalized or
non-functionalized, co, ter polymers, other thermoplastic and
non-thermoplastic resins may be added at a range of 10-90% to
modify end physicals. Melt flow ranges are from 1 to 1000. Loadings
may range from 5 to 95%, final formulation.
[0247] Pigment Polymeric Dispersion (MA Hanna Product #10080332
Grey+Other Sources and Types of Pigment--i.e., Powder, Encapsulated
Spheres, Paste, etc)
[0248] The pigment supplies the color to the system. The particular
pigment that we use is "master batched" in linear-low density
polyethylene. Typical pigment loadings are 0.001 to 50%, final
formulation.
[0249] Antioxidant (Ciba Irgonox 1010+Others)
[0250] The anti-oxidant provides stability to the resin, during
thermal processing and during the coating process. This material is
used as an anti-oxidant to protect the cured resin from thermal
decomposition, upon exposure to the flame applied topcoat. Higher
loading levels show improvement in thermal stability, where lower
levels decrease the thermal stability of the basecoat. Other
"Non-phenol" type anti-oxidants are expected to give the same
results. An example includes thioester amtioxidants. Loadings range
from 0.01 to 5%, final formulation.
[0251] UV Stabilizer (Fairmount Chemical Co. Mixxim BB/100
Benzotriazole Light Stabilizer+Others)
[0252] The stabilizer provides stability to the coating, when
exposed to sunlight and other UV sources. Other light stabilizers
that may be incorporated include: benzophenone, benzotriazole,
triazine, benzoxazinone, hindered amines, and hindered benzoate.
Loadings may range from 0.001% to 5%, final formulation.
[0253] Surfactant (Estron Chemical, Inc. Resiflow LV-67+Others)
[0254] The acrylic is used to improve flow, eliminate air
entrapment, orange peel, pinholes, craters, and other surface
imperfections. This ingredient improves the flexibility of the
coating and provides for better topcoat-basecoat adhesion. A range
of 0.1 to 5%, final formulation is obtainable. Other acrylic
(Solutia.vertline.Modaflow 2100--direct substitute) and non-acrylic
modifiers are expected to yield the same results (i.e., benzoin and
Acetylenic diol's). Ranges are from 0.1 to 5%, final
formulation.
[0255] Amorphous Fumed Silica (Degussa-Huls Corp. Aerosil 200)
[0256] When this material is added as a dry--post additive (to the
finished powder), benefits of enhanced flow of the powder are
realized. Other fillers, especially aluminum oxide may substitute.
Loadings are from 0.0001 to 5%, final formulation.
[0257] This material, if incorporated into the formulation during
the melt mixing portion of the manufacturing, is used as a
thickening agent/anti-sag agent. Decreasing the loading of this
material into the resin decreases the viscosity. Increasing the
loading of this material (up to 10%) increases the viscosity. The
addition of the silica does not significantly affect the
performance, although gloss is matted with incorporation of silica.
The material may be loaded at 0.001 to 10%, final formulation.
Other thickening agents that may substitute include, but are not
limited to the materials listed in the filler portion of this
disclosure (i.e., aluminum oxide). Loadings are anticipated to be
0.1 to 25%, final formulation.
[0258] Fillers
[0259] Fillers common the industry (but not limited to) include:
aluminum oxide, calcium carbonates, dolomite, calcium sulfate,
silicates, glass spheres (solid and hollow), asbestos, talk,
kaolin, mica, feldspar and nepheline syenite, wollastonite,
silicate spheres, silica, natural silicas, synthetic silicas,
adhesion promoters (silanes, titanate, zirconate, and aluminate
coupling agents), molybdenum disulfide, polytetrafluoroethylene,
barium sulfate, metals and metal oxides, aluminum hydroxide,
carbon, fibers (natural and synthetic--basalt, carbon polyamide,
glass, boron, ceramic), electrically conducting fillers (stainless
steel, carbon, carbon fibers, silver coated glass particles), radar
absorbing materials, radiation shielding/EMI shielding (Tungsten
powder), magnetic additives (strontium ferrite and ceramics),
rubber (virgin and re-processed), and sound dampening materials may
be incorporated into the resin to dilute the cost, and/or alter
physical properties. Loadings for fillers may range from 0.01 to
75%, final formulation. Typically increased loadings of fillers
will cause the viscosity of the final formulation to increase.
[0260] Thermal Conductivity Agents
[0261] Zinc Oxide (and other materials such as ceramics), in
addition to reinforcement, also provides resilience and heat
conductivity. This is an important filler, where enhanced thermal
conductivity is of concern. Loadings are typically at 0.1 to 75%,
final formulation.
[0262] Anti-thermal conductive materials (glass and ceramic) may
also be used for the opposite effect. Loadings are at 0.1 to 75%,
final formulation.
[0263] Flame Retardants
[0264] Flame retardants for the formulation are plentiful. Some of
these include: halogen liberating flame retardants, antimony oxide,
phosphorous containing agents, modified silicones, alumina
trihydrate, magnesium hydroxide, organically modified
montmorillonite clay, expandable graphite, boric oxide, zinc
borate, etc. Loadings are typically 0.1 to 60%, final weight.
[0265] Corrosion Inhibiters
[0266] Corrosion protection agents may include polyaniline, amino
tri (methylene-phosphonic acid)--(ATMP), ammonium benzoate, sodium
nitrite, 2-benzothiazolylthio-succinic acid (MBTS), primary,
secondary, and tertiary aliphatic amines, aliphatic diamines,
cycloaliphatic and aromatic amines, polymethylimines, long-chain
ethanolamines, imidazolines, amine salts of carbonic, carbamic,
acetic, benzoic, oleic, nitrous, and chromic acids, acetylenic
alcohols, lauric alcohol, alkyl chromates, organic esters of
nitrous acid, organic esters of phthalic acid, organic esters of
carbonic acid, nitronaphthalene, nitrobenzene, etc. The anticipated
loadings may range from 0.1 to 50%, final formulation.
[0267] Antistatic Agents
[0268] Antistatic agents prevent dust attraction, discharge process
that may damage the product (i.e., packaging and handling of
electronic chips), and curbing spark discharge that can produce
serious accidents. Additives with loadings are at 0.1 to 50%, final
formulation include. Cationic compounds (best effect in polar
substrates), generally consisting of a voluminous cation which
often contains a long alkyl residue (i.e., quaternary ammonium,
phosphonium or sulfonium salt, etc.). In most cases, the anion is
the chloride, methosulfate or nitrate originating from the
quaternization process. Anionic compounds, mostly an alkyl
sulfonate, sulfate or phosphate, a dithiocarbamate or carboxylate,
alkyli metals, etc. Nonionic compounds, uncharged surface-active
molecules including: polyethylene glycol esters or ethers, fatty
acid esters or ethanolamides, mono- or diglycerides or ethoxylated
fatty amines, etc.
[0269] Biostabilizers
[0270] These materials are often used as mold inhibitor
(fungicide), and tannin stain blocking agent. Several commercially
available agents are available, which typically base their
chemistry on organic materials (i.e., Buckman Laboratories). Other
materials may include zinc oxide, copper oxides, etc. The
anticipated loadings are 0.1 to 10%, final formulation.
[0271] Chemical Blowing Agents
[0272] Chemical blowing agents, when incorporated into the
basecoat, release small amounts of gas--resulting in a foamed
material. Examples include a mixture of sodium bicarbonate and
acetic acid, etc. This material is typically incorporated at 0.1 to
10%, final formulation.
[0273] Scent Additives
[0274] Scent additives (such as Stanley S. Schoenmann's products)
provide an array of different fragrances that may be incorporated
into the formulation. Loadings are 0.1 to 25%, final
formulation.
[0275] Bittering Agents and Pepper
[0276] Bitter agents such as ground buffalo gourd may be
incorporated into the coating to prevent damage by livestock (via
oral degradation of the coating). Other ingredients include cyanine
pepper powder, etc. Loadings are typically 0.1 to 25%, final
formulation.
[0277] Pigments/Effects
[0278] Carbon black will cause tensile, modulus, tear, and hardness
to increase, as the carbon loading is increased. In addition,
carbon black gives the formulation the color of black. Typical
loadings range from 0.1 to 40%, final formulation. Many other
organic and inorganic pigments may be used. Specialty pigments,
such as pearl and glow-in-dark may be incorporated.
[0279] Fluorescent Whiting Agents
[0280] Materials such as
2,2'-(2,5-thiophenediyl)bis[5-tert-butylbenzoxazo- le] are often
used to provide brighter looking colors. Typical loadings are 0.1
to 10%, final formulation.
[0281] Lubricants
[0282] Incorporation of lubricants may provide useful properties to
the system. Typical lubricants include: fatty alcohols ant their
dicarboxylic acid esters, fatty acid esters of glycerol and other
short chain alcohols, fatty acids, fatty acid amides, metallic
soaps, oligomeric fatty acid esters (fatty acid complex esters),
fatty acid esters of long-chain alcohols, montanic acid, esters and
soaps, polar polyethylene waxes and their derivatives, nonpolar
polyolefin waxes, natural and synthetic paraffin waxes,
fluoropolymers, and molybdenum disulfide.
[0283] Plasticizers
[0284] Typical plasticizers that may be used include phthalates,
monocarboxylic acid esters, acetates, propionates and butyrates,
esters of ethylbutyric and ethylhexanoic acid, glycolic acid
esters, benzoic acid esters, epoxidized fatty acid esters,
plasticizers based on phthalic acids, aliphatic dicarboxylic acid
esters, phosphates, polyester plasticizers, trimellitic acid
esters, citric acid esters, sulfonic acid esters and sulfamides,
alcohols, ethers and ketones, abietic acid esters, polymerizable
plasticizers, hydrocarbons and halogenated hydrocarbons. Ranges are
from 0.1 to 25%, final weight.
[0285] Other Resins/Blends That May Substitute Main Resin
Components:
[0286] Several other resins and blends thereof, may substitute for
the main resin components quoted above. Examples are shown below in
section J.
[0287] Manufacture--Primer
[0288] 1) Disclosure of preferred alcohol/silane formula (based on
volume % of final formulation):
6 92% Denatured ethyl alcohol (VWR Brand VW0475-7) 5% De-ionized
water 3% Silane mixture (85% methanol, 4% organic phosphonium
chloride salt, and 10% silane monomer)
[0289] Other functional silanes that may substitute include (but
not limited to): alkyd, hydroxy, carboxy, amine, isocyanate
functionality and virtually any other compound containing an active
hydrogen. Also, ionic and anionic silane salts may substitute.
Blends of any above may also work.
[0290] All ingredients are blended at room temperature. The mixture
is allowed to stand for 15 minutes and then is ready for use.
[0291] Chemistries of Alternative Thermoplastic Powder Topcoats
[0292] Alternative resins and blends thereof include (but not
limited to) these plausible thermoplastic resin systems:
ethylene-vinyl acetate, polypropylene, ethylene-methyl acrylate EMA
and ethylene-methyl methacrylate EMAA/polyethylene copolymers,
polyethylene, polyethylene acid terpolymers, polyethylene ionomers,
polyamide co- and ter-polymers, thermoplastic elastomers (TPE's),
acrylonitrile-butadiene-styrene, acrylonitrile halogenated
polyethylene, acrylonitrile halogenated styrene,
acrylic-styrene-acryonitrile, cellulose acetate, cellulose
acetate-butyrate, cellulose acetate-propionate, halogenated
polyethylene, halogenated polyvinyl chloride,
polymonochlorotrifluoroethylene, diallyl phthalate, ethyl
cellulose, ethylene-chlorotrifluroethylene, ethylene-propylene,
tetrafluoroethlyene-hexafluoropropylene-vinylidene fluoride
ter-polymer, EVOH, PEBA, ethylene-tetraflurethylene, fluorinated
ethylene-propylene, high-impact polystyrene, vinyl modified epoxy,
liquid crystal polymer, methacrylate-butadiene-styrene, polyamide,
polyamide-imide, polyacrylonitrile, polybutylene, polybutylene
terephthalate, polycarbonate, polychlorotrifluoroethylene,
polyphenylene ether copolymer, polyetherether ketone, polyphenylene
ether homopolymer, polyetherimide, polyethylene oxide,
polyethersulphone, phenly-formaldeahyde, perfluoroalkoxy,
polyimide, polyisobutylene, polyisoethylene, paramethylstyrene,
polymethylpentene, polyphenylene oxide, polyphenylene sulfide,
polystyrene, polytetrafluoroethylene, polyurethane (polyester and
polyether backbone), polyvinyl chloride, polyvinylidene fluoride,
polyvinyl fluoride, styrene-acrylonitrile, styrene maleic
anhydride, polytetra fluorethylene, urea-formaldehyde, vinyl
acetate-ethylene, polyacetal, polyacrylic, polyalkyd, polyallylic
esters or allyis, cellulosic esters, halogenated polyalkylene
ether, cyanate/cyanamide polymers, halogenated epoxies,
cycloaliphatic epoxys, epoxyimide polymers, polyester polymers,
polyether polymers, and polyphenylene.
[0293] In addition, modifications to the above listed material,
including silane grafting, maleic anhydride grafting, acrylic acid
grafting, and grafting of any functional group containing an active
hydrogen may be used. For example, polyethylene may be modified
(peroxide grafting) to include silane, maleic anhydride, acrylic
acid, or virtually any functional group containing an active
hydrogen.
[0294] Also, co- and poly-polymers utilizing the above resins
and/or modified resins may be used.
[0295] Furthermore, any virtual array of blends utilizing the
aforementioned thermoplastic resins, modified resins, or co - and
poly-polymers of above listed resins may be used.
[0296] Most coatings are acceptable for flame spray/arc-spray/other
thermal spray techniques.
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